Post on 28-Sep-2020
Accepted Manuscript
A flexible and transparent thin film heater based on a carbon fiber /heat-resistantcellulose composite
Pengbo Lu, Fan Cheng, Yanghao Ou, Meiyan Lin, Lingfeng Su, Size Chen, XilangYao, Detao Liu
PII: S0266-3538(17)31739-6
DOI: 10.1016/j.compscitech.2017.09.033
Reference: CSTE 6923
To appear in: Composites Science and Technology
Received Date: 18 July 2017
Revised Date: 5 September 2017
Accepted Date: 11 September 2017
Please cite this article as: Lu P, Cheng F, Ou Y, Lin M, Su L, Chen S, Yao X, Liu D, A flexible andtransparent thin film heater based on a carbon fiber /heat-resistant cellulose composite, CompositesScience and Technology (2017), doi: 10.1016/j.compscitech.2017.09.033.
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A Flexible and Transparent Thin Film Heater Based on a Carbon Fiber /Heat-resistant 1
Cellulose Composite 2
Pengbo Lu, Fan Cheng, Yanghao Ou, Meiyan Lin, Lingfeng Su, Size Chen, Xilang Yao, Detao 3
Liu* 4
State Key Laboratory of Pulp and Paper Engineering, South China University of Technology, 5
Guangzhou 510640, P. R. China 6
Abstract: The thin flexible film heater made of carbon fibers is widely considered to be an ideal 7
material for the use as self-heating devices because of its safe, low-cost, no noises, small size and 8
fast heating as well as energy saving. Presently thin flexible film heater is mostly fabricated by 9
mixing method using the long cellulose fibers as film-forming materials and carbon fibers as 10
self-heating materials, which mostly suffer from opaque or uneven heating field. In this work, we 11
firstly reported a flexible and transparent thin film heater (FTFH) composed of carbon fibers and 12
regenerated cellulose. The use of regenerated cellulose for membrane materials brings high 13
transmittance, strong adhesion, fast temperature response and high generated temperature. More 14
importantly, the FTFH using novel carbon fibers as self-heating materials and regenerated 15
cellulose as membrane materials show a rapid heating response (12 s), higher power density (2577 16
w/m2) and long-term stability of generated temperature (162.3 �). 17
Keywords: Carbon fibers; Flexible composites; Mechanical properties; Thermal properties 18
19
20
1. Introduction 21
*Corresponding author. Tel.: +86 182 0764 1980 Email: dtliu@scut.edu.cn(Dt.L)
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In recent years, design and fabrication of FTFH have attracted significant attentions from 22
both academic and industrial interests [1]. Due to high efficiency in converting electric energy into 23
heat energy, FTFH is widely used in snow-cleaning device, thermal therapies or heating outdoor 24
displays [2-4]. Several emerging materials, including indium tin oxide (ITO), carbon nanotube, 25
metal grids, and grapheme have been studied as self-heating material in FTFH [5-8]. However, 26
their inferior performance and high-cost limit its further application in the next-generation devices. 27
Compared to the other self-heating material in FTFH, carbon fibers were widely considered to be 28
an ideal self-heating materials for use in FTFH because of its high generated temperature, low 29
density, high strength, easy processing and low-cost [9].In particular, much effort has been 30
focused on incorporating carbon fibers into membrane materials, such as cellulose and resin 31
[10,11]. Compared with the other thin flexible film heater, carbon fibers paper (CFP) has been 32
widely used as the thin flexible film heater due to its easy handling, low-cost and high heat 33
generation efficiency [12]. Whereas, research efforts at CFP have encountered numerous problems 34
because the long carbon fibers with high-surface-energy made the CFP opaque and uneven 35
temperature field [13]. Among known strategies for FTFH based on a carbon fiber as the 36
self-heating material, the main membrane materials for it are resin or plant fiber [14]. However, 37
there are several obstacles for these membrane materials to overcome before wide application in 38
thin flexible film heater. For example, the resin can be easily fabricated as a uniform film, but the 39
properties of resin made the thin flexible film heater inflexible [15]. The thin flexible film heater 40
using plant fiber as membrane materials have shown excellent heating performance. However, the 41
poor adhesion of carbon fiber network with the plant fibers made the thin flexible film heater poor 42
mechanical properties and the long fibers made it opaque [16]. Yet, the flexible and transparent 43
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thin film heater with high transmittance (>90%), strong adhesion and fast temperature response 44
can be obtained by means of comprising Ag nanowires (NWs) in an ultrathin polyimide (PI) foil, 45
the process of this flexible and transparent thin film heater is complex and the cost is huge [17]. 46
Contrary to the other membrane materials, the regenerated cellulose is advantageous for practical 47
applications of the flexible and transparent thin film heater, since it will lead to much higher 48
transparency and tensile strength [18]. For this reason, the work presented herein is devoted to 49
obtaining a flexible and transparent thin film heater based on the carbon fiber /heat-resistant 50
cellulose composite by using a very simple and low-cost method. 51
In this paper, we reported a FTFH using regenerated cellulose as a membrane material and 52
carbon fibers as self-heating material. Our FTFH has the following advantages over previously 53
reported materials: (1) The FTFH exhibited uniform heating and rapid thermal response because 54
the regenerated cellulose with a large number of hydroxyl made the carbon fibers disperse evenly. 55
(2) Tensile property and optical transmission have been greatly improved owing to the regenerated 56
cellulose with small size. (3) The FTFH can reach to higher power density and generated 57
temperature. 58
59
60
2 Materials and methods 61
2.1 Materials 62
Commercial eucalyptus dissolving pulp was used as the raw cellulose source material was 63
purchased from Guangzhou Chenhui Paper Co., Ltd. (China). The 6 mm-length carbon fibers were 64
provided by Shanghai Lishuo Co., Ltd. (China); N, N-Dimethylacetamide (DMAC), lithium 65
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chloride (LiCl), supplied by Aladdin-Reagent Co., Ltd. (Shanghai China). Commercial eucalyptus 66
dissolving pulp, DMAC, LiCl, acetone, were used to prepare regenerated cellulose. All the 67
reagents were used as received without further purification. 68
69
2.2 The dissolution of regenerated cellulose 70
The solvent of cellulose was synthesized by according previously reported literature [19]. A 71
specified amount of eucalyptus dissolving pulp was pre-treated by immersing it in acetone for 5 72
min at 25 � and subsequent dissolution of cellulose in 8% LiCl/DMAc (wt/v) solvent through 73
continuous stirring under the anhydrous condition. The process to fully dissolve the cellulose 74
fibers in the LiCl/DMAc took about 3 h at 40 �. Then the cellulose solution was added dropwise 75
into the stirring deionized water at a rate of 20 ml/min to produce the regenerated cellulose. The 76
deionized water was stirred at 5000 r/min to generate strong shear forces and prevent 77
agglomeration using an emulsification machine (Shanghai Yingdi Automation Inc., China). By 78
doing this, the solution of regenerated cellulose was obtained. 79
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2.3 Fabrication of FTFH 81
The method of fabrication for FTFH is briefly described as below. The solution of regenerated 82
cellulose and carbon fibers were dispersed evenly in deionized water by agitating the mixture 83
using a mixer (Shanghai Yingdi Automation Inc., China). The FTFH was prepared by filtering 84
above mixture onto a glass filter with a nylon fabric membrane (pore size: 38 µm). The obtained 85
wet FTFH was repeatedly washed with deionized water to eliminate the residual LiCl or DMAc 86
and then was sandwiched between two stacks of regular filter paper to dry under o.4 MPa pressure 87
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at 110 � for 5 min. The FTFH with base density of 37 g/m2 was obtained using the 88
above-mentioned method. 89
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2.4 Characterizations 91
The structure of the FTFH was studied with a scanning electron microscope (SEM). 92
JEM-100CXII at an accelerating voltage of 10 kV. Prior to the examination, the surface of the 93
specimen was coated with a thin layer of gold, ~20 nm. 94
A KajaaniFS300 Fiber Analyzer was used to quantitatively analyze the dimensions of the 95
regenerated cellulose fibers in the DI water solution and the original cellulose fibers in DI water 96
solution. 97
The mechanical strength of samples was measured using a universal tensile tester (Instron5565, 98
Instron instruments Inc. USA). Samples were firstly cut to 15.0 mm×50.0 mm and placed in 99
constant temperature and humidity chamber at (50±1) % relative humidity (RH) and (23±1) � for 100
24 h to ensure the stabilization of their water content before characterization. 101
UV-Vis spectrometer with an integrating sphere (UV-9000 Shanghai Yuanyi Inc. China) with an 102
integrating sphere was used to measure the total transmittance of the FTFH in a wavelength range 103
of 400 nm to 900 nm. 104
The resistances of the FTFH were recorded by a multimeter (VC890D, China). Samples were 105
firstly cut to 80.0 mm×80.0 mm and placed in constant temperature and humidity chamber at 106
(50±1) % relative humidity (RH) and (23±1) � for 24 h to ensure the stabilization of their water 107
content before characterization. 108
The temperatures and heat distributions of the FTFH were measured using CEM infrared 109
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thermal image (DT-980, China). Samples were firstly cut to 80.0 mm×80.0 mm and placed in 110
constant temperature and humidity chamber at (50±1) % relative humidity (RH) and (23±1) � for 111
24 h to ensure the stabilization of their water content before characterization. The applied DC 112
voltage was supplied by a power supply (HY3005ET, China) to the heater through two copper 113
conductive tapes pasted at the FTFH edges. 114
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3. Results and discussion 116
3.1 Reaction Principle Analysis 117
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Fig. 1. Schematic illustration of the procedure of FTFH. (a) The structure of original cellulose 121
fibers. (b) The structure of regenerated cellulose. (c) The dissolution of regenerated cellulose and 122
the carbon fibers. (d) The FTFH. 123
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125
Cellulose is ideal membrane materials for FTFH due to its easy processing, low-cost, good 126
chemical and biodegrading properties [20]. However, since the original CFP is made of cellulose 127
fibers with diameters of ~20 mm, there are intrinsic disadvantages regarding original CFP. The 128
difference in refractive index between air in pores and the cellulose fibers results in the opaque of 129
the original CFP [21]. The long cellulose fibers also limit its overall mechanical properties due to 130
the tiny amounts of hydrogen bonds. Compared to the CFP made of long cellulose fibers, the 131
FTFH made of regenerated cellulose is recently attracting great attentions by providing excellent 132
mechanical properties, optical transparency [22]. A homogeneous cellulose solution was obtained 133
for preparing the FTFH [23-25]. Subsequently, the regenerated cellulose was obtained by a 134
debonding procedure. The obtained cellulose solution was slowly dropped into the stirring 135
deionized water under the action of high-speed shear force. The hydrogen bond network between 136
the cellulose chains broke again due to the attack from water molecules. The dissolution of 137
regenerated cellulose was prepared because of the interactions between the solvent 138
[26].Afterwards, the carbon fibers with an average length of 6 mm were homogeneously dispersed 139
in the solution of regenerated cellulose. The dispersing performance of carbon fibers is usually 140
unsatisfactory due to carbon fibers with less active groups [27]. In our work, the solution of 141
regenerated cellulose provides an excellent environment for dispersion of carbon fibers because 142
regenerated cellulose has many hydroxyl bonds. The solution with many hydroxyls made the 143
carbon fibers more difficult to flocculate. After that, the wet FTFH was obtained by random 144
deposition of the nylon fabric membrane through vacuum filtration. The FTFH have homogeneous 145
structures, glossy and excellent mechanical properties with acceptable elastic properties. The 146
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reasons for that is the regenerated cellulose with many hydroxyl bonds is considered as the 147
adhesive to bond the neighboring carbon fibers. It was noted that the produced fines (fiber length 148
less than 200 µm) in the regenerate process increased the packing density and filled in the voids 149
between carbon fibers, which undoubtedly increased the packing area and caused the FTFH to 150
exhibit high mechanical strength, acceptable elastic properties and transparency. 151
152
3.2 Properties of transparent paper 153
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Fig. 2. SEM images of the film samples. SEM micrographs of cross-sections: (a) Original 157
paper. (c) RCF. (e) FTFH; SEM micrographs of the fracture surface. (b) Original paper. (d) RCF. 158
(f) FTFH. 159
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161
Table 1. Fiber dimension of regenerated cellulose and the original pulp fibers. 162
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In order to investigate the properties of the samples, the structure of the samples was examined 164
with a scanning electron microscope (SEM). The differences from the ideal structure of original 165
paper to the FTFH samples were distinctly observed from SEM images by scanning cross-sections 166
and fracture surface. The original paper was loosely composed of large pores and long cellulose 167
fibers. The difference in refractive index between air in pores and the basic cellulose results in the 168
opaque of the original paper [28]. The images of original paper made by commercial eucalyptus 169
dissolving pulp through the traditional method were shown (Fig 2a-b). Compared with the images 170
of the film only made from regenerated cellulose (RCF), there is a significant difference between 171
two kinds of film. The film only made from regenerated cellulose (RCF) has no obvious pores on 172
the surface as shown in the SEM image (Fig. 2c). The flat smooth surface of the RCF indicated 173
that the regenerated cellulose is small in size. The regenerated cellulose with small size is highly 174
desirable for achieving good optical and mechanical properties of the resulting thin flexible heater. 175
This RCF also is denser than the original paper sample because the space between regenerated 176
cellulose is smaller than the long cellulose fibers. The images of FTFH were shown (Fig 2e-f). It 177
is clear that the carbon fibers and the regenerated cellulose are well combined with each other. The 178
regenerated cellulose in small size filled out the pores between the carbon fibers and glued on the 179
skeleton of the carbon fibers made the thin flexible film heater is more compact [29]. When the 180
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dosage of carbon fibers increased, this made the crossed network in the film more intensive, which 181
led to the increase in the generated temperature while the transmittance declined for the FTFH. 182
The fiber dimensions for both regenerated cellulose fibers and original pulp fibers were 183
presented in table 1. The regenerated cellulose fibers have an average fiber length of 0.84 mm and 184
an average fiber width of 12.09 µm, which is slightly smaller than original pulp fibers. 185
Regenerated cellulose fibers have a higher curl index (24.56%) but a lower kink index (1063.58 186
1/m) compared to original pulp fibers, which explain the curvy and weavable nature of the 187
regenerated cellulose fibers. The fine content of the regenerated cellulose fibers (fiber length less 188
than 200 µm, 32.33%) is much than higher than that of original pulp fibers (8.31%). Therefore, the 189
basic hydroxyl groups on the surface of the regenerated cellulose fibers enable them to bond 190
tightly through hydrogen bonding pathways, which is similar to the original paper and nanopaper. 191
192
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Fig. 3. The digital images of the RCF, the FTFH-4% and the optical transmittance plot for the 194
conductive nanopaper, RCF, the FTFH-4% and the FTFH -8%. 195
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The optical properties of RCF, the FTFH-4% and the FTFH-8% were compared with a 198
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conductive nanopaper [30] [Fig.3c]. The transmittance of the RCF made by regenerated cellulose 199
at 550 nm reaches up to 63%, which is lower than the conductive nanopaper (81%). The 200
conductive nanopaper is a transparent film made of network-forming nanocellulose fibers and Ag 201
nanowire. These materials are several micrometers long with a diameter of 4–50 nm [31]. As the 202
fiber diameter decreases, the optical transmittance of the film increases [32]. In comparison, 203
although the transmittance of the RCF is lower than the conductive nanopaper, the method of 204
fabrication RCF is greatly easier than the conductive nanopaper and the cost is lower. The 205
meaning of the FTFH-4% is that the sample contains 4% carbon fiber, and the same suits for 206
FTFH-8%. As the content of carbon fibers increases, the optical transmittance of the FTFH 207
decreases. When the content of the carbon fibers is 8%, the transmittance of the film decreases to 208
16%. The reason for the decrease in transparency of FTFH is that the light is hard to penetrate 209
through carbon fibers network. 210
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Fig. 4. (a)Stress-strain curves of the Original paper, the RCF, the FTFH -4% and the FTFH 214
-8%. (b)X-ray diffraction profiles of original paper and the RCF. 215
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The mechanical properties of FTFH play a significant role for the comprehensive device. To 217
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examine the suitability of the samples for industrial applications, the mechanical properties of the 218
original paper, the RCF, the FTFH -4% and the FTFH -8% were determined (Fig.4a). It can be 219
seen that the RCF made from regenerated cellulose caused the most excellent tensile strength, 220
which was suggested by the highest tensile stress (34 MPa). As the content of carbon fibers 221
increases, the tensile stress of the FTFH decreases. The reason for the decrease in the tensile stress 222
of the FTFH is that the carbon fibers with less active groups are difficult to intertwine with 223
regenerated cellulose fibers. The XRD patterns from experiments for the sake of comparison 224
between the original paper and the RCF (Fig.4b). The XRD patterns of the original paper exhibit 225
obvious diffraction peaks at 14.86° and 22.75°, which correspond to the crystalline form of 226
cellulose-I. The RCF shows the diffraction peaks of cellulose II as indicated by the appearance of 227
a board peak at 2θ=20.2°. During regeneration, the dissolving of cellulose fibers in a solvent, 228
which is the main polymorphic modification of cellulose, causes a rearrangement of the crystal 229
packing of chains from native cellulose I to cellulose II. 230
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Fig. 5. (a) A digital image of FTFH which illustrates its excellent optical and conductive 235
properties. (b)The power density of FTFH and the CFP; (c) the resistance of FTFH and the CFP 236
with the content of carbon fibers ranging from 4% to 12%; (d) the generated temperature of the 237
FTFH with the carbon fibers content of 12% at various voltages ranging from 5 V to 30 V. 238
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The performance of the power density of FTFH was compared with CFP that composed of long 241
cellulose fibers and carbon fibers with the same length [Fig.5b] [33]. And the resistance of FTFH 242
and the CFP with the content of carbon fibers ranging from 4% to 12% were shown [Fig.5c]. As 243
the content of carbon fibers increases, the power density of FTFH increases and the resistance of 244
the FTFH decrease. It can be observed that the FTFT exhibited a higher power density compared 245
to the CFP. When the content of carbon fibers is 12%, the power density can reach to 2577 w/m2, 246
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which is higher than the CFP. The improved power density of the FTFH could be mainly 247
attributed to the compact contact between carbon fibers and good adhesion of the carbon fibers to 248
the substrate. The generated temperature of the FTFH with the carbon fibers content of 12% at 249
various voltages were shown [Fig.5d]. When the voltages were set as 5, 10, 15, 20, 25 and 30 V, 250
the FTFH can reach to the temperature of 33.5, 41.9, 67.5, 90.6, 128.3 and 162.3�, respectively. 251
Therefore, the same FTFH could be used to meet different temperature requirements by simply 252
applying an appropriate voltage. Contrary to the long cellulose fibers, the network of carbon fibers 253
can be formed easily due to the regenerated cellulose with small size in FTFH. These results 254
indicate that the use of regenerated cellulose as membrane materials has enormous potential in the 255
fabrication of FTFH. 256
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Fig. 6. (a) Digital image of the FTFH with carbon fibers content 2 %; The infrared thermal 262
images of the film samples, the CFP with carbon fibers content of (b) 4%, (c) 8% and (d) 12%, the 263
FTFH with carbon fibers content of (e) 4%, (f) 8% and (g) 12%. 264
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The temperature evolution of the FTFH and the CFP with carbon content fibers of 4%, 8% and 266
12% were shown in Fig 6, respectively. All samples were driven at 20 V for 12 s. One of the 267
intriguing properties of the thin flexible film heater is their high heat generation efficiency. By 268
passing the current through the FTFH, they could be quickly heated from room temperature to a 269
steady temperature of 36.3 �, 59.9 � and 88.2 �, respectively. The presence of high generated 270
temperature will be desirable for self-heating heater devices. As the content of carbon fibers 271
increases, the generated temperature of the FTFH increases. The results indicated that the 272
generated temperature of the FTFH is tuned depending on the content of the carbon fibers. 273
Compared with the CFP with the same length and content of carbon fibers, the generated 274
temperature of FTFH is significantly higher than it. Its good heating performance was attributed to 275
its low resistance of the FTFH, which was improved by introducing regenerated cellulose with 276
small size enabling enhanced overlapping between the carbon fibers. Therefore, we propose that 277
the FTFH with industrially scalable could be fabricated, revealing a bright application prospect in 278
a large-areas heating production, such as heating in outdoors displays, defogging in vehicles, or 279
thermal therapies. 280
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Fig. 7. (a) The generated temperature - response time of the FTFH and the CFP with the content 284
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of 12% at 20 V; (b) the resistance - time of the FTFH with various carbon fibers content. 285
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The response time is also an important part to evaluate the performance of the thin flexible film 288
heater. Both the FTFH and the CFP can reach to saturation temperature in 12 s. The results proved 289
that the carbon fibers are good self-heating material to use in the thin flexible film heater. The 290
stability of the resistance of the thin flexible film heater is essential for the sake of safety. To 291
examine the stability of the resistance of FTFH for safety, the change of the resistance of the 292
FTFH along the time was determined (Fig.7b). The resistance is no obvious change along the time. 293
Only when the first thirty minutes the resistance slightly increased due to the rise of the 294
temperature of the FTFH. Then the resistance maintains a steady value in about two hours. The 295
properties of the FTFH meet the requirement of the use of the thin flexible film heater due to 296
shorter response time, the stability of the resistance and higher generated temperature. 297
298
4. Conclusions 299
300
The FTFH with high optimal transmittance, excellent tensile strength, and higher generated 301
temperature has been successfully fabricated using novel carbon fibers as self-heating material and 302
regenerated cellulose as membrane materials. The FTFH based on carbon fibers-regenerated 303
cellulose composite generated hot temperature saturation up to 162 � at 30 V, exhibits shorter 304
response time and long-term stability of resistance. The performance attributes of FTFH are all 305
higher than the previously reported CFP. These results suggest that the use of regenerated 306
cellulose as membrane materials has enormous potential in the fabrication of FTFH. For device 307
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applications, the FTFH should be a suitable material as outdoor display panels, defrosters in 308
vehicles, and other devices experiencing large temperature variations. This work is expected to be 309
helpful for the development of the flexible and transparent thin film heater for the fabrication of 310
large-scale, uniform film heaters. 311
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Acknowledgments 328
This work was supported by funding received from State Key Laboratory of Pulp and Paper 329
Engineering (Grant No. 2016C08), Guangzhou Science and Technology Plan Project (Grant 330
No.201704030066), kindly supported by Guangdong Province Youth Science and Technology 331
Innovation Talents (Grant No. 2014TQ01C781) and the Fundamental Research Funds for the 332
Central Universities (Grant No.2017ZD087) South China University of Technology. 333
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